Reverse osmosis water-on-water control valve

ABSTRACT

Described are water-on-water valves for use in reverse osmosis filtration systems. The water-on-water valves are regulated by the pressure in a product line, which contains fluid from a product line of the filter module and/or the product side of a water-on-water storage tank. Exemplary valves are shuttle valves that are regulated by the pressure downstream of the product side of a reverse osmosis filter module. The valves may comprise a piston within a housing, and an end of the piston may have an enlarged diameter relative to the maximum diameter of the remainder of the piston. The body of the piston may have sections of differing diameters, where the smaller diameter sections form flow channels, or the body may a diameter that is substantially the same along its length in conjunction with gratings and flow channels.

TECHNICAL FIELD

Embodiments of the present invention generally relate to filtrationsystems, in particular water-on-water control valves and reverse osmosissystems including such valves.

BACKGROUND

Various water filtration systems designed for residential and commercialuse have become increasingly popular for the removal of unwantedsubstances from input water. Filtration systems utilize a filter modulesuch as a reverse osmosis filter module to provide filtered output waterfor consumption or other use.

Two common water filtration systems are air-on-water systems thatdischarge product water into an enclosed pressure vessel against backpressure created by an air compartment within the vessel, andwater-on-water systems that discharge product water into an enclosedpressure vessel and into a flexible water compartment that can becompressed by a separate source of water to remove the product waterfrom the vessel.

In air-on-water systems, the water storage tank is divided into twocompartments. The first compartment is for holding product water and thesecond compartment is filled with a pre-charge of air. As the filtrationsystem produces water and fills the storage tank, the air compartment iscompressed to accommodate the volume of product water introduced intothe product compartment, which increases the air pressure. That increasein air pressure continues to rise for every ounce of product waterforced into the storage tank. As such, air-on-water systems are subjectto the back pressure of the air compartment, which causes the pressuredifferential across the filtering portion of the system to be reduced.This reduction in pressure differential thereby reduces the quality andquantity of filtered product water made in a given time. Product waterquality particularly suffers if the product water is frequently drawnoff and replaced in small quantities, as typically occurs in householdsystems. Moreover, an air-on-water system does not provide a constantflow rate of product water because the air compartment gradually losespressure as the air compartment-propelled water is emptied from thestorage vessel.

Water-on-water systems can address many of the shortcomings ofair-on-water systems. Water-on-water systems typically include apressure vessel containing two water-filled compartments. Often, a firstcompartment stores product water and a second compartment contains“squeeze” water. A physical separation between the compartments ismovable or flexible so that water pressure in the first compartment isinfluenced by the water pressure in the second compartment. Thus,pressure from the “squeeze” side can discharge water from the productside to a faucet or other outlet downstream when there is a waterdemand. The physical separation between the compartments can be amembrane or other similar structure. In these water-on-water systems,there is only a small amount of backpressure acting upon the membrane,which is the amount of pressure required to force water from the squeezecompartment to the drain as the product compartment is filled.

There is a continuing need for improved water-on-water valves andfiltration systems using such valves.

SUMMARY

One aspect of the present invention pertains to a filtration systemcomprising a water-on-water storage tank comprising a squeeze side and aproduct side separated by a membrane; a filter module in fluidcommunication with the water-on-water storage tank, a feed source, aproduct outlet, and a drain outlet; a feed line connecting the feedsource to a feed inlet of the filter module; a product line connecting afiltrate outlet of the filter module to the product side of the storagetank and the product outlet; and a drain line connecting a reject outletof the filter module to the squeeze side of the storage tank and thedrain outlet of the system; and a valve or a combination of valves thatregulates the flow from the feed source, wherein pressure in the productline determines the state of the valve or the combination of valves.

In one or more embodiments, the valve or the combination of valves hasat least three states, wherein: the first state enables flow from thefeed source to the filter module and from a reject outlet of the filtermodule to the squeeze side of the storage tank when there is flowthrough the product outlet, the second state enables flow from the feedsource to the filter module and from the squeeze side of the storagetank to the drain outlet of the system when there is not flow throughthe product outlet and the product side is not full, and the third stateblocks flow from the feed source into the filtration system when theproduct side is full.

The filter module may comprise a reverse osmosis filter. In one or moreembodiments, the filter module also comprises one or more pre-filtersupstream of the reverse osmosis filter. In some embodiments, the filtermodule comprises a post-filter downstream from the product side of thestorage tank.

The filtration system may also comprise one or more check valves, suchas a check valve downstream from a filtrate outlet of the filter modulethat prevents fluid flow into the filtrate outlet of the filter module.Another check valve may be placed downstream from the product side andupstream of the valve or the combination of valves to maintain a holdpressure during the third state.

In one or more embodiments, the filtration system may comprise a flowcontrol regulator that regulates flow from a reject outlet of the filtermodule to the drain outlet of the system when the valve is in the firststate.

One or more embodiments provide that the valve comprises a shuttle valveor a multiport valve. If the valve is a shuttle valve, in someembodiments, an end portion of the shuttle valve is in communicationwith the pressure downstream of the product side. If the valve is amultiport valve, in some embodiments, a controller for the multiportvalve is in communication with the pressure downstream of the productside.

Other embodiments provide that the system is regulated by a combinationof valves. In these embodiments, the combination of valves may comprisea plurality of valves and a controller. Some embodiments provide thatthe controller is in communication with the pressure downstream of theproduct side.

Another aspect of the present invention relates to a reverse osmosiswater-on-water valve comprising a valve feed inlet port, a valve feedoutlet port, a drain port, a reject port, and a tank squeeze port. Inembodiments of this aspect, the valve has at least three states, whereinin the first state, a first fluid path is defined by the valve feedinlet port that is in fluid communication with the valve feed outletport, and a second fluid path is defined by the reject port that is influid communication with the tank squeeze port; in the second state, athird fluid path is defined by the valve feed inlet port that is influid communication with the valve feed outlet port, and a fourth fluidpath is defined by the tank squeeze port that is in fluid communicationwith the drain port; and in the third state, the valve feed inlet portis not in fluid communication with the valve feed outlet port.

In some embodiments, the valve may be a solenoid-controlled multiportvalve or a combination of solenoid-controlled valves.

In some embodiments, the valve may be a shuttle valve. The shuttle valvemay comprise a piston body in a housing, the piston body having a firstend potion connected to a spring. Some embodiments provide that thepressure on a second end portion of the piston body determines whetherthe valve is in the first, second, or third state.

In one or more embodiments, the piston body further comprises a pistonface at the second end portion of the piston body, wherein a diameter ofthe piston face is greater than a maximum diameter of the piston body.The piston body may comprise a plurality of sections, with a first groupof sections each independently having a first diameter effective toblock flow from or to one or more of the following: the valve feed inletport, the valve feed outlet port, the drain port, the reject port, andthe tank squeeze port depending on the state of the valve, and a secondgroup of sections each independently having a reduced diameter withrespect to one or more of the first diameters, effective to permit flowfrom or to one or more of the following: the valve feed inlet port, thevalve feed outlet port, the drain port, the reject port, and the tanksqueeze port depending on the state of the valve. The first group ofsections may be arranged in an alternating arrangement with the secondgroup of sections.

In other embodiments, the piston body comprises a plurality of sections,a first group of sections each independently having a solid surfaceeffective to block flow from or to one or more of the following: thevalve feed inlet port, the valve feed outlet port, the drain port, thereject port, and the tank squeeze port depending on the state of thevalve, and a second group of sections each independently having aplurality of channels effective to permit flow from or to one or more ofthe following: the valve feed inlet port, the valve feed outlet port,the drain port, the reject port, and the tank squeeze port depending onthe state of the valve. The channels may independently comprise lineargrating or spiral grating to define the channels. The piston body mayhave a diameter that is substantially the same along its length.

The piston body may also comprise a flow slot to allow fluidcommunication between the valve feed inlet port and the valve feedoutlet port as the valve moves from the third state to the first state.

In some embodiments, the housing includes one or more vents through thehousing to allow air to be vented as the piston body moves betweenstates. The one or more vents may be on the first end of the piston,second end of the piston, or both.

The housing may also comprise a chamber in fluid communication with thesecond end portion of the piston body, wherein changes in pressure inthe chamber cause the piston to move. The chamber may comprise thereinan inlet check valve and an outlet check valve, wherein the inlet checkvalve has a cracking pressure greater than a cracking pressure of theoutlet check valve.

The valve may also comprise a plurality of sealing devices whichseparate fluid paths during the various states. In some embodiments, thesealing devices are effective to separate the first fluid path from thesecond fluid path during the first state and are effective to separatethe third fluid path from the fourth fluid path during the second state.

A valve in accordance with this aspect or any embodiments describedherein may be utilized in a filtration system. Such a filtration systemmay comprise a water-on-water storage tank comprising a squeeze side anda product side separated by a membrane; a filter module connected to afeed source by a feed line, to a product outlet by a product line, andto a drain outlet by a drain line; and the valve. In some embodiments,the pressure of the product line may determine the state of the valve. Acheck valve may be located in the product line to maintain a holdpressure on the valve during the third state.

Another aspect of the present invention relates to a method of providingfiltered water with a filtration system. In embodiments of this aspect,the method comprises introducing feed water into a valve or acombination of valves, delivering the feed water from the valve to afilter module, filtering the feed water with the filter module toprovide filtered water and reject water, storing filtered water in awater-on-water storage tank, dispensing filtered water from thewater-on-water storage tank to a product outlet through a product line,and discarding reject water through a drain outlet. In some embodiments,the pressure in the product line determines the state of the valve orthe combination of valves.

In one or more embodiments, the valve comprises: a valve feed inletport, a valve feed outlet port, a drain port, a reject port, and a tanksqueeze port. The valve may have at least three states, wherein: in thefirst state, a first fluid path is defined by the valve feed inlet portthat is in fluid communication with the valve feed outlet port, and asecond fluid path is defined by the reject port that is in fluidcommunication with the tank squeeze port; in the second state, a thirdfluid path is defined by the valve feed inlet port that is in fluidcommunication with the valve feed outlet port, and a fourth fluid pathis defined by the tank squeeze port that is in fluid communication withthe drain port; and in the third state, the valve feed inlet port is notin fluid communication with the valve feed outlet port. In someembodiments, the valve comprises a shuttle valve.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments of the disclosurein connection with the accompanying drawings, in which:

FIG. 1 is a schematic of a reverse osmosis filtration system inaccordance with one or more embodiments of the invention;

FIGS. 2-4 are cross-section views of a shuttle valve in three differentstates in accordance with one or more embodiments of the invention;

FIG. 5 is a schematic drawing of an exemplary system;

FIG. 6 is a schematic drawing of a piston body according to the pistonbody shown in FIG. 1; and

FIGS. 7 & 8 are schematic drawings of other embodiments of a pistonbody.

The figures are not necessarily to scale. Like numbers used in thefigures refer to like components. It will be understood, however, thatthe use of a number to refer to a component in a given figure is notintended to limit the component in another figure labeled with the samenumber.

DETAILED DESCRIPTION

Provided are water-on-water control valves for use in reverse osmosis orother filtration systems. In various embodiments, the water-on-watervalves are regulated by the pressure in the product line, which containsfluid from a product line of the filter module and/or the product sideof a water-on-water storage tank. In some embodiments, use of theproduct line pressure instead of the reject line pressure may reducevalve chatter with low demand flow rates. Use of product line pressuremay also reduce the likelihood that the valve will stall in thetransition state.

Current water-on-water systems still have certain disadvantages. Thecontrol valve of the system may stall or freeze if another water demandoccurs when the valve is in a transition state. After stalling, theremay be a long time delay before the valve can self-recover and beginwater production. Valve chatter may also occur if there is a very lowdemand flow rate, such as from an ice maker. Furthermore, the initialstartup procedure may be difficult because the water-on-water storagetank needs to be purged of air before the valve can operate. Startup mayrequire filling the product compartment, followed by filling the squeezecompartment, then filling the product compartment again. It hasunexpectedly been found that use of pressure in the product line toregulate the state or configuration of the control valve addressescertain disadvantages of current water-on-water systems.

Although specific reference is made to reverse osmosis filtrationsystems, the water-on-water valves and systems described herein may beused with other similar fluid filtration systems.

As used herein, a tensioner or spring refers to any component thatprovides a tension or compression force that pulls or pushes on anothercomponent. In some embodiments, the tensioner or spring is aconventional spring that applies a force dependent on the displacementof the spring. Types of springs include, but are not limited to,cantilever springs, helical springs, balance springs, leaf springs,V-springs, Belleville springs, gas springs, compression springs,extension springs, torsion springs and constant force springs.

As used herein, a filter module refers to one or more filtration membersor filter elements that remove impurities or other undesirable substancefrom a fluid. The filter module may consist of a single filter element,or may comprise a plurality of filtering elements. In one or moreembodiments, the filter module comprises a reverse osmosis filterelement. In various embodiments, the filter module includes additionalfilter elements such as pre-filters, post-filters or additional reverseosmosis filter elements.

As used herein, a pressure fuse refers to a component that regulates thepressure downstream from the fuse such that the downstream pressure doesnot exceed a trip pressure. The term pressure fuse is a general termthat encompasses both resettable and non-resettable devices. Suitablepressure fuses are described in co-owned U.S. Patent App. No.61/667,103, filed Jul. 2, 2012, which is herein incorporated byreference in its entirety.

Reference to a “shuttle valve” refers to a body with multiple, forexample three or more, openings in combination with an internalstructure that moves within the body to block one or more of theopenings.

One aspect provided herein relates to a filtration system for filteringfluid or water from a feed source to provide an output of product water.In FIG. 5, general filtration system 500 is shown. A valve orcombination of valves 505 controls flow from one or more inputs to oneor more outputs. Also part of the system are a filter element 532 and awater-on-water storage tank 502. The filter element 532 has a filtrateoutlet 531 from which filtered fluid or water exits as product fluid orwater and a reject outlet 533 from which reject fluid or water flows.The water-on-water storage tank 502 has a product side or compartment508 that can receive the product fluid or water and a squeeze side orcompartment 506 that can receive reject fluid or water. Flow paths arebased on pressure in the product line 525 wherein the valve orcombination of valves enters a particular state that enables aparticular flow path. Flows paths can be as follows. A first flow pathin the first state is defined by a valve feed inlet port 516 that is influid communication with a valve feed outlet port 518, and a secondfluid path is defined by a reject port 520 that is in fluidcommunication with a tank squeeze port 522. In a second state, a thirdfluid path is defined by the valve feed inlet port 516 that is in fluidcommunication with the valve feed outlet port 518, and a fourth fluidpath is defined by the tank squeeze port 522 that is in fluidcommunication with a drain port 524. In a third state, the valve feedinlet port 516 is not in fluid communication with the valve feed outletport 518. A filter module can be one or more structures that purify afluid such as water, where the purified fluid or output water exits fromthe system through a filtrate outlet 531. For example, the filter modulemay include the filter element 532, pre-filters prior to the filterelement and/or post-filters after the filter element. The filter element532 receives feed source fluid or water to be filtered through feed line515 and feed inlet 517. Filtrate or product fluid or water exits thefilter element through the filtrate outlet 531 and through product line525 to the product side 508 and/or the product outlet 544. Reject fluidor water exits the filter element through reject outlet 533 and travelsthrough drain line 535 to the drain outlet 542 or the squeeze side 506.Product line 525 can be in contact with the valve 505 forhydraulically-operated valves and for mechanical valves, such contact isnot necessary. A check valve 538 is in communication with the valve 505,and it maintains a hold pressure when the product compartment is full tokeep the valve 505 in position for a particular state, such as arecovery state and a rest state.

FIG. 1 shows a detailed exemplary filtration system 100 in accordancewith one or more embodiments. Filtration system 100 includes awater-on-water storage tank 102, a control valve 105 and a filterelement 132. Storage tank 102 includes a first compartment 108 forstoring product water and a second compartment 106 for storing squeezewater. A divider 104 separates the storage tank 102 into the product andsqueeze sides or compartments. The divider 104 may be a membrane, bag,diaphragm or other similar structure for physically separating theproduct side from the squeeze side, but allowing the pressure from thesqueeze compartment 106 to act upon the fluid in the product compartment108. Likewise, pressure from the product compartment 108 acts upon thesqueeze compartment 106.

The filter element 132 is in fluid communication with a feed source 114,a drain outlet 142 and a product outlet, such as a faucet, 144. Throughthe filter element 132, the filtration system 100 filters fluid fromfeed source 114 to provide an output of product water to product outlet144, with remaining reject water flowing to drain outlet 142. Forexample, if filter element 132 is a reverse osmosis filter element, thenthe product water exiting the filtrate outlet 131 of the filter element132 will have a lower solids or impurities content than the fluid fromfeed source 114, and the reject water will have a higher concentrationof solids or impurities than the feed source fluid. Accordingly, thereject water that exits through the reject outlet 133 of filter element132 is a byproduct of the reverse osmosis process and is disposed ofthrough drain outlet 142. The filtrate outlet 131 of filter element 132may be in fluid communication with a check valve 136 to protect againstbackpressure on the filter element 132.

The filtration system may also include a feed line 115 connecting thefeed source 114 to the feed inlet 117 of the filter element 132, aproduct line 125 connecting the filtrate outlet 131 of the filterelement 132 to the product compartment 108 of the storage tank 102 andthe product outlet 144 of the system, and a drain line 135 connectingthe reject outlet 133 of the filter element 132 to the squeezecompartment 106 of the storage tank 102 and the drain outlet 142 of thesystem.

The feed line 115 may also fluidly connect a pressure fuse 128 and oneor more pre-filters 130 to the feed inlet of the filter element 132.Pressure fuse 128 may be a device that ensures the pressure downstreamof the pressure fuse 128 does not exceed a threshold value by acting asa “fuse”. When the pressure at the pressure fuse 128 reaches or exceedsthe threshold value, the pressure fuse 128 will trip and preventcomponents downstream of the pressure fuse 128 from being exposed to thepressure increase. In this way, the pressure fuse 128 operates similarlyto an electrical fuse or circuit breaker. The pressure fuse may beresettable or non-resettable, depending on the use. The filter element132 may be part of a filter module 137 which may include additionalcomponents, such as a pre-filter 130 or a post-filter 134. Thepre-filter 130 may filter the fluid before it reaches the primary filterelement 132.

A post-filter 134 may be placed in the product line 125 to be apolishing filter before delivering the water to the product outlet 144.The post-filter 134 may be downstream of both the product side of thefilter element 132 and the product compartment 108.

A valve or combination of valves 105 controls the flow of fluid into thesystem and to the various components of filtration system 100. The valve105 may be a shuttle valve comprising a piston body 110, a spring 112and a plurality of ports 116, 118, 120, 122 and 124. The arrangement andconnectivity of the ports 116, 118, 120, 122 and 124 can be varied toprovide numerous potential configurations for regulating the fluid flowthrough the filtration system 100. More or fewer ports may be utilized.In one or more embodiments, port 116 may be a valve feed inlet port toreceive fluid from feed source 114, port 118 may be a valve feed outletport to provide feed source fluid to the filter element 132, port 120may be a reject port to receive reject water from the filter element132, port 122 may be a tank squeeze port to send fluid to and receivefluid from the squeeze compartment 106, and port 124 may be a drain portto provide reject water to the drain outlet 142. Alternatively, insteadof using a single multi-port valve, a combination of valves each havingat least one inlet port and at least one outlet port may be used. Thoseskilled in the art will recognize that many potential configurations ofvalves may be used to provide the desired regulation of fluid flowthrough the filtration system.

One or more O-rings 158 may separate fluid flows through the valve 105to prevent mixing of fluid streams, as well as prevent water leakage outof the valve.

The control valve 105 may have a plurality of states that each providesdifferent flows through the system. According to one or moreembodiments, the state of the control valve 105 is determined by apressure downstream of the product compartment 108. For example, thepressure in the product line 125 at the end potion 126 of the pistonbody 110 may determine the state of the control valve 105.

The control valve or combination of valves 105 may be hydraulicallycontrolled by the fluid pressure, or may be electromechanicallycontrolled. Examples of suitable hydraulic valves include shuttlevalves. Examples of valves suitable for electromechanical controlinclude solenoid controlled valves, ball valves, spherical valves andplug valves. In embodiments that the control valve(s) areelectromechanically controlled, a control system may control the stateof the valve(s) 105 through the use of one or more solenoids or electricmotors. The control system may be in communication with pressure sensorsor flow sensors located throughout the filtration system. The controlsystem may use these pressure or flow sensors to determine when there isa water demand and adjust the state of the control valve(s) 105accordingly. For example, if a pressure sensor measures a drop in thepressure of product line 125, the control system may shift the valve 105from the rest state to the dispensing state. Thus, even if a controlsystem is used to control the state of the valve 105, the valve statemay indirectly be determined by the pressure or flow in the product line125.

The plurality of states can be referred to as at rest, dispensing, andrecovery. In FIG. 1, the configuration shown is “dispensing,” where whenthere is a water demand, such as from a drinking faucet or ice maker,from product outlet 144, a hold pressure on end portion 126 is reducedto about 0 psig and spring 112 extends to its full length. In thisstate, the control valve 105 enables flow from the feed source 114 intothe valve feed inlet port 116 and out of valve feet outlet port 118. Thecontrol valve 105 also permits fluid communication between the rejectoutlet 133 of the filter element 132 through reject port 120 and thesqueeze compartment 106 of the storage tank 102 through tank squeezeport 122. There is no fluid communication through drain port 124 duringthe dispensing state. The feed water travels down the length of a scrollof the filter element 132 (sometimes referred to as “fast flush”) beforeentering the tank squeeze port 122 in the valve 105 and then to thesqueeze compartment 106 of the tank.

As the reject water enters the squeeze compartment 106, water is forcedout of the product compartment 108. At this point, the pressure at thebottom of the product compartment 108 will be equal to the pressure dropthrough the post-filter 134, the resistance in the downstream lines andany flow control in the faucet or other product outlet 144. The rejectwater may flow through a flow control regulator 140 that regulates theflow to the drain outlet 142.

When the water demand ends, the control valve 105 continues to allowfluid from the feed source 114 into the system. The filter element 132continues to produce product fluid, and the pressure in the product line125 and product compartment 108 will rise. Once a certain pressure isreached, the control valve 105 may shift to a “recovery” state.According to one or more embodiments, this shift occurs due to thepressure at the end portion 126 overcoming the force of the spring 112.

In the recovery state, the control valve 105 maintains fluidcommunication from the feed source 114 into the filtration system. Thecontrol valve 105 also places the squeeze compartment 106 through tanksqueeze port 122 in fluid communication with the drain outlet 142through drain port 124. Once the squeeze compartment 106 is connected tothe drain outlet 142, the back pressure of the storage tank 102approaches 0 psi. However, a check valve 138 near the end portion 126 ofthe control valve 105 maintains a hold pressure obtained when theproduct compartment was full to keep the control valve 105 in positionfor the recovery state and the rest state as discussed below. The filterelement 132 continues to make product water and fill the productcompartment 108, which forces squeeze water out of the squeezecompartment 106 of the storage tank 102. Because the squeeze compartment106 of the tank is open to drain in the recovery state, the backpressure on the divider 102 is only that required to force the water outof the squeeze compartment 106 to the drain outlet 142.

At the same time the filter element 132 is filling the productcompartment 108 of the storage tank 102 with product water, the rejectwater is being force through a flow control regulator 140 that appliesthe pressure required for reverse osmosis. This continues until theproduct compartment 108 is full.

When the product compartment 108 is full and the feed source is stillentering into the system, the filter element 132 will continue to filterwater. Because there is no outlet for the product water, pressure willrise in the system and in the product line 125 adjacent the end portion126. When the pressure reaches the pressure for the “at rest” state,(such as about 25 psig), the valve 105 will move to compress the spring112 (to the right of FIG. 1) and the feed source passage will be shutoff. Pressure will over time relieve to 0 psig through the flow controlregulator 140 and once the pressure drops below the osmotic pressure thefilter element 132 will no longer make product water. This will shut offthe system until the next water demand.

During the time after recovery and until the next water demand, thecontrol valve is “at rest”. In this state, the product compartment 108of the storage tank 102 is filled with fluid, and the control valve 105prevents flow from the feed source 114 into the filtration system 100.In this state, the storage tank 102, post filter 134 and the end portion126 of the control valve 105 may be at about the same pressure. Thispressure may be varied depending on the design of the control valve, butin some embodiments may be in the range from about 10 psig to about 50psig. In some embodiments, the pressure at the end portion 126 is in therange from about 20 psig to about 30 psig, such as about 25 psig. Thispressure against the end portion 126 of the control valve 105 holds thevalve in the at rest position against the force of the spring 112. Thesqueeze compartment 106 of the tank and the reject line from the filterelement 132 may be open to the drain outlet 142. The pre-filter 130 andfilter module 132 may be at about 0 psig because both components areisolated from feed water pressure and water hammer events.

Another aspect herein pertains to a control valve that may be used in areverse osmosis filtration system. This control valve may be used in afiltration system as described above. In one or more embodiments of thisaspect, the valve comprises a piston body in a housing, and the pistonbody has a first end potion connected to a spring. The valve also has afeed inlet port, a feed outlet port, a drain port, a reject port, and atank squeeze port. The valve also has a plurality of states that definedifferent fluid paths between the ports.

In the first state, which may be a “dispensing” state, a first fluidpath is defined by the valve feed inlet port that is in fluidcommunication with the valve feed outlet port, and a second fluid pathis defined by the reject port that is in fluid communication with thetank squeeze port. In the second state, which may be a “recovery” state,a third fluid path is defined by the valve feed inlet port that is influid communication with the valve feed outlet port, and a fourth fluidpath is defined by the tank squeeze port that is in fluid communicationwith the drain port. The third fluid path of the second state may be thesame as the first fluid path in the first state, or the two fluid pathsmay be different. In the third state, which may be an “at rest” state,the valve feed inlet port is not in fluid communication with the valvefeed outlet port. In one or more embodiments, the O-rings and/or theshape of the piston body is effective to separate the first fluid pathfrom the second fluid path in the first state, and during the secondstate, is effective to separate the third fluid path from the fourthfluid path.

An exemplary embodiment of a control valve in the rest state is shown inFIG. 2. The valve 205 shown in FIG. 2 has a piston body 210 in a housing246. The configuration of the ports 216, 218, 220, 222 and 224 ofcontrol valve 205 in FIG. 2 is an alternate configuration of the ports116, 118, 120, 122 and 124 of the control valve 105 in FIG. 1. A spring212 acts upon a first end of the piston body. A second end of the pistonbody 226 may have a piston face 227. The force of the spring 212 actsagainst the force provided by the pressure at the piston face 227. Inone or more embodiments, the diameter of the piston face 227 is greaterthan the maximum diameter of the remaining piston body 210. If thepiston face 227 has an enlarged diameter relative to the remainingpiston body 210, the friction force on the piston body 210 is relativelylow compared to the force from the pressure at the piston face 227. Useof an enlarged-diameter piston face 227 also allows the use of a stifferspring 212. In one or more embodiments, the piston face has a diameterin the range from 0.25 inches to 2.5 inches (that is, the diameter sizecan include, but is not limited to: 0.25, 0.5, 0.75, 1.0, 1.25, 1.5,1.75, 2.0, 2.25, or even 2.50 inches) or has a surface area in the rangefrom 0.05 square inches to 5 square inches (that is, the surface areacan be, but is not limited to: 0.05, 0.2, 0.4, 0.8, 1.2, 1.8, 2.4, 3.1,4.0, or even 4.9 square inches). Also, in one or more embodiments, thespring has a spring rate in the range from 10 pounds per inch to 60pounds per inch (that is, the spring rate can be 10, 15, 20, 25, 30, 35,40, 45, 50, 55, or even 60 psi).

The second end 226 may be enclosed in a chamber 248. The chamber 248 maycomprise an inlet check valve 250 and an outlet check valve 252. Thechamber may be in fluid communication with a product line 225(corresponding to product line 125 in FIG. 1) that carries filteredfluid from a filtrate outlet of a filter module to a product outlet suchas a faucet. In some embodiments, the inlet check valve 250 has acracking pressure greater than a cracking pressure of the outlet checkvalve 252. A “strong” inlet check valve 250 may create a more dynamicpressure introduction to the valve to help overcome O-ring staticfriction. Also, a “weak” outlet check valve 252 paired with the stronginlet check valve 252 may allow substantially all of the water to flowout of the chamber 248, and thus the piston 210 may move freely whenthere is a water demand and the system needs to respond. A check valve238 (corresponding to check valve 138 in FIG. 1) may also help capturepressure downstream of the check valve 238 to maintain the control valvein a particular state. In one or more embodiments, check valve 238 mayhave a cracking pressure in the range from 0 to 0.5 psi, check valve 250may have a cracking pressure in the range from 20 to 60 psi and checkvalve 252 may have a cracking pressure in the range from 0 to 5 psi.

The housing may have a valve feed inlet port 216, a valve feed outletport 218, a reject port 220, a tank squeeze port 222 and a drain port224. The piston body 210 may have a plurality of sections comprising afirst group of sections 254 and a second group of sections 256. Thefirst group of sections 254 may each independently have a first diametereffective to block flow from or to one or more of the following: thevalve feed inlet port 216, the valve feed outlet port 218, the rejectport 220, the tank squeeze port 222, and the drain port 224, dependingon the state of the valve. The second group of sections 256 may eachindependently have a reduced diameter with respect to one or more of thefirst diameters of the first group of sections 254, with the reduceddiameters effective to permit flow from or to one or more of thefollowing: the valve feed inlet port 216, the valve feed outlet port218, the reject port 220, the tank squeeze port 222, and the drain port224, depending on the state of the valve. One or more sealing devices258 may also block flow between two or more ports, or prevent flow outof the housing 246. The sealing devices may be O-rings, gaskets and thelike. The housing may also include one or more vents 260 to allow forair venting as the control valve moves between states.

As shown in FIG. 2, the rest state of the control valve may block fluidflow from the feed inlet port 216 to the feed outlet port 218. A portion254 and O-ring 258 may provide a tight seal so that the fluid flow isprevented between these ports. The configuration of the feed inlet port216 and feed outlet port 218 shown in FIG. 2 allows the feed pressure topress the O-ring tightly against the seal. The rest state may also allowfluid to flow from the tank squeeze port 222 to the drain port 224.

FIG. 3 shows an exemplary control valve in the dispensing state. Thefeed inlet port 216 is in fluid communication with the feed outlet port218, and the reject port 220 is in fluid communication with the tanksqueeze port 222. The valve may be in this state when there is a waterdemand, and thus enable fluid flow from a product compartment and to aproduct outlet.

As the valve transitions from the rest state to the dispensing state,the O-ring 258 between the feed inlet port 216 and the feed outlet port218 may grab the piston body 210, thus preventing piston movement andthereby preventing flow communication across the O-ring 258.Accordingly, in some embodiments, the piston body includes a flow slot262 or other groove to allow communication as soon as the piston movesany distance. Such a flow slot 262 can therefore assist in allowing thevalve to turn on and move to the dispensing state.

FIG. 4 shows a control valve in the recovery state. In this state, thefeed inlet port 216 is in fluid communication with the feed outlet port218, and the tank squeeze port 222 is in fluid communication with thedrain port 224. The control valve may be in this state once there is nolonger a water demand, and a storage tank is filled with product waterfrom a reverse osmosis filtration module. Once the storage tank is full,the resulting increase in pressure at the piston face 227 moves thevalve from the recovery state to the rest state.

In FIG. 6, a schematic drawing of the piston body 110 according to FIG.1 is shown, showing in detail where there are reduced diametricalsections 111 to facilitate fluid communication between the various flowports, i.e., valve feed inlet port, valve feed outlet port, reject port,tank squeeze port, and drain port. These reduced diametrical sectionspass underneath fixed o-ring seals during operation. Seal stretch andcompression over the piston body is lost then regained during valvemovement. Flow slot 162 or other groove may allow communication betweenthe ports as soon as the piston moves any distance.

In FIGS. 7-8, schematic drawings of other embodiments of a piston bodyare provided where the piston body has a diameter that is substantiallythe same along its length. In FIGS. 7-8, piston bodies 710 and 810contains gratings 752 and 852 to form spiral channels 750 and linearchannels 850, respectively, to facilitate fluid communication betweenthe various flow ports. By replacing the reduced diametrical sections ofFIG. 6 with gratings 752 and 852 having substantially the same elevationas the rest of the body and including spiral channels 750 or linearchannels 850 acting as flow channels, the o-ring seals do not changeelevation during operation. This means that stretch and compression overthe piston body may be maintained there-by reducing the force requiredto regain this seal during transition. In this way, less force would beneeded to operate a valve containing piston bodies according to FIGS.7-8 as compared to those of FIG. 6. In a non-limiting, detailedembodiment, when using a piston body according to FIG. 7 or 8, a pistonface may have a cross-section area that is 1 in² and a spring that has aspring rate of 25 lbs. per foot.

Another aspect pertains to a method of providing filtered water with afiltration system. The method may comprise any of the steps describedherein. In one or more embodiments of this aspect, the method comprisesintroducing feed water into a valve, delivering the feed water from thevalve to a filter module, filtering the feed water with the filtermodule to provide filtered water and reject water, storing filteredwater in a water-on-water storage tank, dispensing filtered water fromthe storage tank to a product outlet of the system, and discardingreject water through a drain outlet of the system.

The valve may have any of the features of a control valve describedabove. In one or more embodiments, the valve comprises a valve feedinlet port, a valve feed outlet port, a drain port, a reject port, and atank squeeze port. The valve may have a plurality of states thatregulate fluid flow through the system. In some embodiments, in thefirst state, a first fluid path is defined by the valve feed inlet portthat is in fluid communication with the valve feed outlet port, and asecond fluid path is defined by the reject port that is in fluidcommunication with the tank squeeze port. In some embodiments, in thesecond state, a third fluid path is defined by the valve feed inlet portthat is in fluid communication with the valve feed outlet port, and afourth fluid path is defined by the tank squeeze port that is in fluidcommunication with the drain port. In some embodiments, in the thirdstate, the valve feed inlet port is not in fluid communication with thevalve feed outlet port.

In one or more embodiments, the valve is a hydraulic valve operated bywater pressure of the system. In other embodiments, the valve is anelectromechanical valve operated by a control system responding topressure or flow sensors at various locations in the system.

Although the invention herein has been described with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It will be apparent to those skilled in the art thatvarious modifications and variations can be made to the method andapparatus of the present invention without departing from the spirit andscope of the invention. Thus, it is intended that the present inventioninclude modifications and variations that are within the scope of theappended claims and their equivalents.

1. A filtration system comprising: a water-on-water storage tankcomprising a squeeze side and a product side separated by a membrane; afilter module in fluid communication with the water-on-water storagetank, a feed source, a product outlet, and a drain outlet; a feed lineconnecting the feed source to a feed inlet of the filter module; aproduct line connecting a filtrate outlet of the filter module to theproduct side of the storage tank and the product outlet; and a drainline connecting a reject outlet of the filter module to the squeeze sideof the storage tank and the drain outlet of the system; and a shuttlevalve that regulates the flow from the feed source, wherein pressure inthe product line determines the state of the shuttle valve; wherein theshuttle valve comprises a piston body having a plurality of sections, afirst group of sections each independently being effective to block flowfrom or to one or more of the following: the valve feed inlet port, thevalve feed outlet port, the drain port, the reject port, and the tanksqueeze port depending on the state of the valve, and a second group ofsections each being effective to permit flow from or to one or more ofthe following: the valve feed inlet port, the valve feed outlet port,the drain port, the reject port, and the tank squeeze port depending onthe state of the valve.
 2. The filtration system of claim 1, wherein theshuttle valve has at least three states, wherein: the first stateenables flow from the feed source to the filter module and from a rejectoutlet of the filter module to the squeeze side of the storage tank whenthere is flow through the product outlet, the second state enables flowfrom the feed source to the filter module and from the squeeze side ofthe storage tank to the drain outlet of the system when there is notflow through the product outlet and the product side is not full, andthe third state blocks flow from the feed source into the filtrationsystem when the product side is full.
 3. The filtration system of claim1, wherein the filter module comprises a reverse osmosis filter.
 4. Thefiltration system of claim 3, wherein the filter module comprises one ormore pre-filters upstream of the reverse osmosis filter.
 5. Thefiltration system of claim 3, wherein the filter module comprises apost-filter downstream from the product side of the storage tank.
 6. Thefiltration system of claim 1, further comprising a check valvedownstream from a filtrate outlet of the filter module that preventsfluid flow into the filtrate outlet of the filter module.
 7. Thefiltration system of claim 2, further comprising a flow controlregulator that regulates flow from a reject outlet of the filter moduleto the drain outlet of the system when the valve is in the first state.8. The filtration system of claim 1, wherein an end portion of theshuttle valve is in communication with the pressure downstream of theproduct side.
 9. The filtration system of claim 2, further comprising acheck valve downstream from the product side and upstream of the valveor the combination of valves to maintain a hold pressure during thethird state.
 10. A reverse osmosis water-on-water valve comprising: avalve feed inlet port, a valve feed outlet port, a drain port, a rejectport, and a tank squeeze port, wherein the valve has at least threestates, wherein: in the first state, a first fluid path is defined bythe valve feed inlet port that is in fluid communication with the valvefeed outlet port, and a second fluid path is defined by the reject portthat is in fluid communication with the tank squeeze port; in the secondstate, a third fluid path is defined by the valve feed inlet port thatis in fluid communication with the valve feed outlet port, and a fourthfluid path is defined by the tank squeeze port that is in fluidcommunication with the drain port; and in the third state, the valvefeed inlet port is not in fluid communication with the valve feed outletport; wherein the valve is a shuttle valve comprising a piston body in ahousing, the piston body having a first end potion connected to aspring; and wherein the piston body comprises a plurality of sections, afirst group of sections each independently having a solid surfaceeffective to block flow from or to one or more of the following: thevalve feed inlet port, the valve feed outlet port, the drain port, thereject port, and the tank squeeze port depending on the state of thevalve, and a second group of sections each independently having aplurality of channels effective to permit flow from or to one or more ofthe following: the valve feed inlet port, the valve feed outlet port,the drain port, the reject port, and the tank squeeze port depending onthe state of the valve.
 11. The valve of claim 10, wherein pressure on asecond end portion of the piston body determines whether the valve is inthe first, second, or third state.
 12. The valve of claim 11, whereinthe piston body further comprises a piston face at a second end of thebody, wherein a diameter of the piston face is greater than a maximumdiameter of the piston body.
 13. The valve of claim 10, wherein thepiston body further comprises a flow slot to allow fluid communicationbetween the valve feed inlet port and the valve feed outlet port as thevalve moves from the third state to the first state.
 14. The valve ofclaim 10, further comprising a vent through the housing to allow air tobe vented as the piston body moves between states.
 15. The valve ofclaim 10, further comprising a plurality of sealing devices, whichduring the first state, are effective to separate the first fluid pathfrom the second fluid path, and during the second state, are effectiveto separate the third fluid path from the fourth fluid path.
 16. Thevalve of claim 10, wherein the housing comprises a chamber in fluidcommunication with the second end portion of the piston body, whereinchanges in pressure in the chamber cause the piston to move.
 17. Thevalve of claim 16, wherein the chamber comprises therein an inlet checkvalve and an outlet check valve, wherein the inlet check valve has acracking pressure greater than a cracking pressure of the outlet checkvalve.
 18. The valve of claim 10, wherein the plurality of channelsindependently comprise linear grating or spiral grating to define thechannels.
 19. The valve of claim 10, wherein the piston body has adiameter that is substantially the same along its length.
 20. Afiltration system comprising: a water-on-water storage tank comprising asqueeze side and a product side separated by a membrane; a filter moduleconnected to a feed source by a feed line, to a product outlet by aproduct line, and to a drain outlet by a drain line; and the valve ofclaim
 10. 21. A method of providing filtered water with a filtrationsystem, the method comprising: introducing feed water into the valve ofclaim 10; delivering the feed water from the valve to a filter module;filtering the feed water with the filter module to provide filteredwater and reject water; storing filtered water in a water-on-waterstorage tank; dispensing filtered water from the water-on-water storagetank to a product outlet through a product line; and discarding rejectwater through a drain outlet, wherein pressure in the product linedetermines the state of the valve or the combination of valves.